Vehicle Segment:
Heavy-duty utility and recreational ATV
Target Audience:
Off-road enthusiasts, hunters, farmers, and recreational riders seeking a capable and comfortable touring ATV.
Key Competitors 2008:
Can-Am Outlander, Yamaha Grizzly, Honda Foreman/Rancher, Suzuki KingQuad
Touring Focus:
Designed for longer rides and passenger comfort with a comfortable seat and extended wheelbase.
Efi Technology:
Electronic Fuel Injection for improved throttle response, fuel efficiency, and cold-weather starting.
Aawd System:
On-Demand All-Wheel Drive for enhanced traction in challenging terrain.
Diy Repair Benefit:
Empowers owners to perform maintenance and repairs themselves, saving on labor costs and ensuring quality.
Engine:
Complete engine overhaul, diagnostics, specifications, troubleshooting for the 500cc EFI engine.
Fuel System:
EFI system components, fuel pump, injectors, pressure regulator, troubleshooting, and maintenance.
Ignition System:
Ignition coil, CDI unit, spark plug, timing, and troubleshooting.
Cooling System:
Radiator, fan, thermostat, coolant, and related components.
Transmission Drivetrain:
Automatic transmission (PVT - Polaris Variable Transmission), clutch system, drive belts, gearcase, differentials, AWD system, drivelines, and CV joints.
Braking System:
Hydraulic brake system (front and rear calipers, master cylinders), brake lines, pads, discs, bleeding procedures, and parking brake.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, switches, fuses, and relays.
Suspension Steering:
Front and rear suspension (struts, shocks, control arms), wheel bearings, steering system components, tie rods, and alignment.
Body Chassis:
Frame, body panels, plastics, seats, racks, and mounting hardware.
Lubrication Maintenance:
Scheduled maintenance, fluid capacities, lubrication points, and filter replacement.
Troubleshooting:
Diagnostic procedures for common problems, fault codes (if applicable to EFI), and systematic problem-solving.
Routine Maintenance:
Oil changes, filter replacements (air, oil, fuel), spark plug service, battery checks, chain/belt adjustments (if applicable), and general inspections.
Engine Repairs:
Top-end rebuild (cylinder head, piston), valve adjustment, camshaft replacement, crankshaft service, and seal replacement.
Fuel System Service:
Injector cleaning, fuel pump testing, pressure checks, fuel filter replacement.
Transmission Service:
Drive belt inspection and replacement, clutch inspection and adjustment, gearcase oil changes, differential service.
Brake System Service:
Brake pad replacement, caliper service, master cylinder rebuild, brake line bleeding.
Electrical Diagnostics:
Charging system testing, starter motor diagnosis, lighting circuit troubleshooting, use of wiring diagrams.
Suspension And Steering Repair:
Shock absorber replacement, ball joint inspection, tie rod end replacement, wheel bearing replacement.
Overhaul Rebuilds:
Detailed instructions for complete disassembly, inspection, repair, and reassembly of major components.
Depth Of Coverage:
Comprehensive (covers routine maintenance, diagnostics, repair, and complete overhauls)
Diagnostic Capabilities:
Detailed troubleshooting charts and procedures for identifying and resolving mechanical and electrical issues.
Specification Detail:
Includes critical torque specifications, clearances, fluid types, capacities, and electrical values.
Engine Type:
4-stroke, SOHC, 4-valve, single cylinder
Displacement:
499cc (30.45 cu. in.)
Bore X Stroke:
92 mm x 74 mm (3.62 in. x 2.91 in.)
Cooling System:
Liquid-cooled
Horsepower Estimated:
Approx. 35-40 HP (Varies based on tuning and source)
Torque Estimated:
Approx. 28-30 lb-ft (Varies based on tuning and source)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (87 octane minimum)
Ignition Type:
Digital CDI with electronic advance
Oil Type:
SAE 10W-50 (Polaris recommends specific ATV oil, consult manual for exact spec)
Oil Capacity:
Approx. 2.0 US quarts (1.9 L) with filter change
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (or per manual recommendation).
Air Filter Cleaning:
Clean every 25 hours, replace as needed (more frequently in dusty conditions).
Spark Plug Replacement:
Check and clean every 50 hours, replace every 100 hours or as needed.
Drive Belt Inspection:
Inspect every 50 hours, replace as needed or at recommended intervals (typically 1200-1500 hours, but early inspection is crucial).
Gearcase Oil Change:
Every 100 hours or annually.
Engine Oil Specification:
Polaris Synthetic 10W-50 4-Cycle ATV Engine Oil or equivalent meeting API SG/SH/SJ or JASO MA standards.
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water recommended).
Charging System Issues:
Stator and regulator/rectifier failures can be common on some Polaris models of this era. Regular testing is advised.
Cv Joint Boots:
Torn CV joint boots can lead to premature wear of the joints; regular inspection and maintenance are crucial.
Efi Sensor Issues:
While generally reliable, sensors like the throttle position sensor (TPS) or crank position sensor can occasionally cause running issues.